Lancing as a position locator in an electrical outlet box

ABSTRACT

An electrical receptacle has at least one side wall defining a receptacle interior, wherein the side wall includes an edge defining a receptacle opening and further includes at least one raised protrusion formed thereon and an aperture formed therein as a result of forming the protrusion. The protrusion has a banking surface substantially parallel with the opening edge for positioning the receptacle and the protrusion substantially occludes access to the receptacle interior through the aperture of the side wall.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/309,021, filed on Jul. 31, 2001.

FIELD OF THE INVENTION

The present invention relates generally to an electrical receptacle andmore particularly to an electrical receptacle having protrusions formedthereon as position locators.

BACKGROUND OF THE INVENTION

Means for positioning an electrical outlet box with respect to astructural element to which it is mounted are well known in the art. Forexample, U.S. Pat. No. 4,842,165 to Nattell discloses an electricaloutlet box having positioning elements similar to that shown in FIG. 1.Referring to FIG. 1, the electrical outlet box 10 includes locatingfingers 12 formed on the sidewalls 14 of the box. The locating fingers12 are bent transversely from the sidewall 14 about bend lines extendingparallel to the front of the box 10. The locating fingers 12 are bankedagainst a structural element, such as a wall stud 16, so as to positionthe electrical box a predetermined distance forward of the structuralelement. Typically, the distance between the front of the electrical box10 and the banking surface of the fingers 12 is equal to the thicknessof a subsequently installed wall so that the front of the box 10 will beflush against the finished wall.

One disadvantage of the locating finger arrangement shown in FIG. 1 isthat these fingers can only be formed at the ends of a sidewall. Hence,their use is limited. Another disadvantage is that these outwardlyprojecting locating fingers typically include sharp edges makinghandling of the electrical box for installation difficult andinconvenient.

Another example of an electrical outlet box having a positioning meansis described in U.S. Pat. No. 5,579,939 to Bourassa and shown in FIG. 2.Here, the electrical outlet box 20 includes tabs 22 projecting outwardlyfrom a side wall 24 of the box. Again, the tabs 22 are spaced an equaldistance from the edge of the front opening of the box and are setagainst a side of an adjacent supporting structure 26 so as to positionthe box 20 a predetermined distance forward from the structure. The tabs22 are formed by punching out small portions of the sidewall 24 andbending the punched out portions perpendicularly, leaving openings orholes 27 in the side wall. Although here the tabs 22 may be positionedanywhere on the side wall, they typically still include sharp edgesmaking handling of the box difficult.

Another disadvantage of the configuration shown in FIG. 2 relates to theresulting holes or apertures 27 formed in the side wall of the box as aresult of the punching process. North American electrical standardsrequire that an electrical outlet box be fabricated such as to not allowa 0.118 inch diameter rod to simultaneously pass through both sidewalls. Therefore, an electrical outlet box formed with tabs 22,according to FIG. 2, can have the tabs only on one of the side walls inorder to meet the standards. If the tabs 22 were formed on both sidewalls, a 0.118-inch diameter rod would be able to pass through the holes27 formed on both side walls. Such a box would not be in compliance withNorth American electrical standards.

Another positioning element found in both electrical boxes of FIGS. 1and 2 is an arrangement of raised convex projections or bosses 28 formedon one or both side walls of the box. However, these bosses 28 only aidin laterally spacing the electrical box a distance away from thesupporting structure and do not provide front to back alignment of theelectrical box.

Accordingly, it would be desirable to provide an electrical outlet boxhaving a position locator to aid in front to back alignment of the boxthat meets North American electrical standards and is easier to handlewhen installing.

SUMMARY OF THE INVENTION

The present invention is an electrical receptacle having at least oneside wall defining a receptacle interior. The side wall includes an edgedefining a receptacle opening and further includes at least one raisedprotrusion formed thereon. The protrusion has a banking surfacesubstantially parallel with the opening edge and the protrusionsubstantially occludes access to the receptacle interior through anaperture formed as a result of forming the protrusion on the side wall.

The protrusion can be any shape. For example, the protrusion can bearcuate shaped or peak shaped and can be completely integral with theside wall. In a preferred embodiment, the banking surface of theprotrusion is also substantially perpendicular to the side wall and isspaced a predetermined distance from the opening edge of the receptacle.The protrusion is a substantially integral outwardly bent portion of theside wall, whereby a 0.118 inch diameter rod can not be inserted throughthe aperture below the protrusion. The side wall preferably includes tworaised protrusions, which have coplanar banking surfaces that aresubstantially parallel with the opening edge. The side wall furtherpreferably includes at least one convex boss formed thereon. The convexboss has a predetermined height for spacing the side wall apredetermined distance away from a structural mounting element.

Preferably, the receptacle includes a top wall, a bottom wall, a backwall and two side walls forming an open rectangular box. A first sidewall includes a first raised protrusion formed thereon and a second sidewall includes a second raised protrusion formed thereon. The first andsecond protrusions each have a banking surface substantially parallelwith the opening edge, and the protrusions substantially occlude accessto the receptacle interior through the first and second side walls. In apreferred embodiment, the banking surface of the first protrusion isspaced a first predetermined distance from the opening edge and thebanking surface of the second protrusion is spaced a secondpredetermined distance from the opening edge.

The present invention also involves a method for forming a positioningprotrusion for an electrical receptacle. The method includes the stepsof cutting two substantially parallel slits in a side wall of anelectrical receptacle and bending a portion of the side wall between theslits outwardly to form the positioning protrusion. The slits are cutsubstantially parallel with an opening edge of the receptacle so thatthe positioning protrusion will be formed having a banking surfacesubstantially parallel with the opening edge. In forming the protrusionin this manner, the positioning protrusion will substantially occludeaccess to the interior of the receptacle through the side wall.

A preferred form of the electrical receptacle having protrusions as aposition locator as well as other embodiments, features and advantagesof this invention, will be apparent from the following detaileddescription, which is to be read in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a prior art electrical outlet box having locatingfingers.

FIG. 2 illustrates a prior art electrical outlet box having outwardlyprojecting locator tabs.

FIG. 3 is a perspective view of the electrical box formed in accordancewith the present invention.

FIG. 4 is a side view of a lancing taken along line 4—4 of FIG. 3.

FIG. 5 is a perspective view of an alternative embodiment of aprotrusion formed in accordance with the present invention.

FIG. 6 is a perspective view of another alternative embodiment of aprotrusion.

FIG. 7 is a perspective view of still another alternative embodiment ofa protrusion.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to FIG. 3, an electrical receptacle 30 formed inaccordance with the present invention is shown. The electricalreceptacle 30 shown in FIG. 3 includes top and bottom walls 32 a backwall 34 and side walls 36 a and 36 b forming an open rectangular boxhaving an interior 37. However, the receptacle 30 can take any shape. Atleast one, and preferably both, side walls 36 a and 36 b are formed withat least one protrusion, called a lancing, 38 a and 38 b that projectsoutwardly from the side wall. Preferably, each side wall 36 a and 36 bincludes two protrusions or lancings 38 a and 38 b positioned apredetermined distance from the front opening edge 42 of the box 30. Theprotrusions 38 a on one side wall 36 a can be positioned a firstpredetermined distance 40 from the edge 42 and the protrusions 38 b onthe other side wall 36 b can be positioned a second predetermineddistance 41 from the edge. For example, standard wall board sizes are ½inch and ⅜ inch. Accordingly, one set of protrusions 38 a can be spaced½ inch from the edge 42 and the protrusions 38 b on the opposite sidewall can be spaced ⅜ inch from the edge. This provides the receptacle 30with alternate front to back positioning depending on which side wall 36a or 36 b is mounted to the supporting structure 46.

The protrusions 38 a and 38 b are preferably formed using known lancingforming techniques. In particular, the protrusions 38 a and 38 b areformed in the side walls 36 a and 36 b by a dye that cuts parallel slits43 in the side walls. The slits 43 are formed parallel to the openingedge 42 of the sidewall 36 a and 36 b. The die further bends the portionof the side wall between the slits outwardly to form the protrusion 38 aand 38 b. Thus, in the preferred embodiment, the protrusion 38 a and 38b is not entirely punched out of the side wall 36 a and 36 b, therebyleaving no sharp edges. Additionally, the protrusion 38 a and 38 bsubstantially occludes or blocks the resulting aperture 39 in the sidewall 36 so that a 0.118 inch diameter rod will not be able to fit intothe interior 37 of the electrical box 30. As a result, protrusions 38 aand 38 b can be provided on both side walls 36 a and 36 b and the box 30will still meet North American electrical standards.

As also shown in FIG. 4, the protrusions 38 thus formed include abanking surface 44 that is parallel to the opening edge 42 of thereceptacle and preferably perpendicular to the side wall 36. The bankingsurface 44 of the protrusion 38 is used to position the electrical box30 a predetermined distance forward of a supporting structure 46. If twoprotrusions 38 are formed in the side wall 36, the banking surfaces 44of each protrusion should be coplanar and aligned parallel with thefront edge 42 of the electrical box 30 to ensure level alignment of thebox.

The protrusions 38 can take many shapes so long as the protrusionincludes a banking surface parallel with the front opening of thereceptacle and so long as the protrusion substantially occludes accessto the interior of the receptacle through the side wall. The protrusions38 a and 38 b shown in FIGS. 3 and 4 are arcuate in shape and are formedby cutting parallel slits 43 into the side wall 36 a and 36 b. Thus, theside wall 36 a and 36 b has an aperture 39 and the protrusion 38 a and38 b is integral with the side wall at its longitudinal ends. FIG. 5shows a protrusion 50 that is completely integral with the side wall 36,whereby no aperture is formed in the side wall. FIG. 6 shows aprotrusion 52 that is triangular or peak shaped and FIG. 7 shows aprotrusion 54 that is similar to the protrusion 38 shown in FIGS. 3 and4, but is integral with the side wall 36 only at one end. In each of theembodiments shown in FIGS. 5-7, the protrusion 50, 52 and 54 includes abanking surface 44 parallel to and spaced from the opening edge 42 ofthe receptacle. Additionally, each of the protrusions 50, 52 and 54occludes or blocks access to the interior of the receptacle through theside wall 36.

The protrusions discussed thus far are all formed from a portion of thereceptacle box side wall. However, it is conceivable that a protrusionhaving a banking surface can be formed separately from the receptacleand attached to the receptacle to cover an aperture formed in thereceptacle side wall. In such case, the banking surface is positionedover the side wall aperture to occlude or block access to the interiorof the receptacle through the side wall aperture. The banking surfacecan then be attached to the side wall by known fastening techniques, forexample, by welding or riveting.

Returning to FIG. 3, the side walls 36 a and 36 b further preferablyinclude one or more convex bosses 48 formed therein. The bosses 48 areformed having a selected height 49 to provide a predetermined spacingbetween the supporting structure 46 and the receptacle 30 oninstallation. To install the receptacle 30, the banking surfaces 44 ofthe protrusions 38 are banked up against the front face of thesupporting structure 46 and the convex bosses 48 are rested against theside face of the supporting structure. The receptacle 30 can then besecured to the supporting structure in a known manner, for example, byscrews or nails.

Thus, the electrical receptacle 30 formed in accordance with the presentinvention provides positive front to back positioning with respect to asupporting structure. Additionally, the protrusions of the presentinvention can be formed on both side walls. If the spacing of theprotrusions with respect to the front edge of the receptacle is the sameon both side walls, proper orientation of the receptacle duringinstallation is less critical. If the spacing is different, theinstaller can orient the receptacle to select the desired positioning,depending on the chosen finished wall thickness. Because the openingsformed in the side walls during the lancing forming process areoccluded, a rod will not be able to pass through both side walls of thebox and, therefore, North American electrical standards are met.Finally, the lancings are shaped smooth leaving no sharp edges.Therefore, the box is easier to handle during installation.

Although the illustrative embodiments of the present invention have beendescribed herein with reference to the accompanying drawings, it is tobe understood that the invention in not limited to those preciseembodiments and various other changes maybe effected herein by oneskilled in the art without departing from the scope or sprit of theinvention.

What is claimed is:
 1. An electrical receptacle comprising at least oneside wall defining a receptacle interior, said side wall including anedge defining a receptacle opening and said side wall further includingat least one raised protrusion formed thereon and an aperture formedtherein as a result of forming said protrusion, said protrusion having abanking surface substantially parallel with said opening edge, andwherein said protrusion substantially occludes access to said receptacleinterior through said aperture of said side wall.
 2. A receptacle asdefined in claim 1, comprising a top wall, a bottom wall, a back walland two side walls forming an open rectangular box.
 3. A receptacle asdefined in claim 1, wherein said banking surface of said protrusion issubstantially perpendicular to said at least one side wall.
 4. Areceptacle as defined in claim 1, wherein said banking surface of saidprotrusion is spaced a predetermined distance from said opening edge. 5.A receptacle as defined in claim 1, wherein said protrusion is asubstantially integral outwardly bent portion of said side wall.
 6. Areceptacle as defined in claim 1, wherein said protrusion substantiallyoccludes said aperture whereby a 0.118 inch diameter rod can not beinserted through said aperture.
 7. A receptacle as defined in claim 1,wherein said side wall includes two raised protrusions, each protrusionhaving a banking surface substantially parallel with said opening edge.8. A receptacle as defined in claim 7, wherein the banking surfaces ofthe two raised protrusions are coplanar.
 9. A receptacle as defined inclaim 1, comprising first and second opposite side walls defining areceptacle interior, each of said side walls including an edge defininga receptacle opening and said first side wall further including a firstraised protrusion formed thereon and said second side wall furtherincluding a second raised protrusion formed thereon, each of said firstand second protrusions having a banking surface substantially parallelwith said opening edge, and wherein said first and second protrusionssubstantially occlude access to said receptacle interior through saidfirst and second side walls.
 10. A receptacle as defined in claim 9,wherein said first side wall further includes a first aperture formed asa result of forming said first protrusion and said second side wallfurther includes a second aperture formed as a result of forming saidsecond protrusion, wherein said first and second protrusionsrespectively substantially occlude access to said receptacle interiorthrough said first and second apertures of said first and second sidewalls.
 11. A receptacle as defined in claim 10, wherein said first andsecond protrusions respectively substantially occlude said first andsecond apertures whereby a 0.118 inch diameter rod can not be insertedthrough both said first and second side walls through said first andsecond apertures.
 12. A receptacle as defined in claim 9, wherein saidbanking surface of said first protrusion is spaced a first predetermineddistance from said opening edge and said banking surface of said secondprotrusion is spaced a second predetermined distance from said openingedge.
 13. A receptacle as defined in claim 9, wherein said bankingsurface of said first protrusion is substantially perpendicular to saidfirst side wall and said banking surface of said second protrusion issubstantially perpendicular to said second side wall.
 14. A receptacleas defined in claim 1, wherein said side wall further includes at leastone convex boss formed thereon, said boss having a predetermined heightfor spacing said side wall a predetermined distance away from astructural mounting element.
 15. A receptacle as defined in claim 1,wherein said protrusion is arcuate shaped.
 16. A receptacle as definedin claim 1, wherein said protrusion is peak shaped.
 17. A receptacle asdefined in claim 1, wherein said protrusion is partially integral withsaid side wall.
 18. An electrical receptacle comprising at least oneside wall defining a receptacle interior, said side wall including anedge defining a receptacle opening and said side wall further includingat least one aperture formed therein and a banking surface disposed oversaid aperture, said banking surface being substantially parallel withsaid opening edge, wherein said banking surface substantially occludesaccess to said receptacle interior through said aperture of said sidewall.
 19. An electrical receptacle as defined in claim 18, wherein saidbanking surface is formed from a portion of said side wall.